Topology Optimization Design of Ram Structure for ECM Machine Tool
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摘要: 滑枕是电解加工机床中的关键承载件，对机床的加工性能有至关重要的影响。针对滑枕部件的结构特点及受载情况，采用了设置加强筋提高滑枕结构刚度的技术方案，并对受力变形情况进行了有限元仿真分析。在此基础上，基于拓扑优化方法，建立多约束优化数学模型，利用评价函数将多目标问题转化为单目标问题求解，以最小质量作为优化目标函数，最大变形量作为约束条件，开展了优化设计并进行了灵敏度分析，以此获得了合理的加强筋布局和结构尺寸，在有效提高了滑枕部件刚度和承载稳定性的同时，实现了轻量化设计。该滑枕部件已实际应用于自行研制的电解加工机床中。Abstract: As the key structure of the ECM machine tool, the ram has great important influence on the performance of the machine tool. In this paper, the structural characteristics and loading conditions of ram are analyzed, and the design scheme of stiffener is put forward, and the stress and deformation condition is simulated via finite element method. On the above-mentioned basis, the mathematical model for the multi constraint optimization is established so as to transform the multi-objective problem into single objective problem via evaluation function by using the topology optimization method. Adopting the minimum mass as optimization objective function and the maximum deformation as constraint condition, the structural optimization design and the sensitivity analysis of the optimized parameters is carried out. The result shows that the stiffener layout is reasonable, and meanwhile the ram structure performance is improved and the lightweight design is achieved. The ram has been used in the self-made ECM machine tool.
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Key words:
- electrochemical machining /
- ram /
- rigidity /
- topology optimization /
- sensitivity analysis
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表 2 不同结构形式的滑枕性能参数对比
结构形式 X1/mm X2/mm X3/mm 最大变形量/mm 刚度/(N·mm-1) 质量/kg 无加强筋 20 0 0 0.083 7 2.688×104 12.4 有加强筋 20 18 50 0.005 28 4.261×105 16.59 拓扑优化后 20.125 10.1 0.625 0.024 87 9.047×104 13.46 
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表 3 与滑枕最大变形量、刚度、质量有关的灵敏度和相对灵敏度
设计变量 变形灵敏度
ST刚度灵敏度
SF/(N·mm-2)质量灵敏度
SM/(kg·mm-1)相对灵敏度 初值/mm 下限值/mm 上限值/mm ST/SM SF/SM X1 20 15 25 -0.003 132 7 730.923 7 0.361 1 -0.008 64 21 409.37 X2 10 5 15 -0.001 265 3 528.107 6 0.0973 4 -0.012 99 36 245.19
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